Hilti DD 500-CA Operating instructions

DD 500-CA
Hilti
Brand
Hilti
Model
DD 500-CA
Category
Power tools
Type
Operating instructions
DD 500-CA
Bedienungsanleitung de
Operating instructions en
Mode d’emploi fr
Istruzioni d’uso it
Manual de instrucciones es
Manual de instruções pt
Gebruiksaanwijzing nl
Brugsanvisning da
Bruksanvisning sv
Bruksanvisning no
Käyttöohje
Οδηγιεςχρησεως el
Használati utasítás hu
Instrukcjaobsługi pl
Инструкцияпозксплуатации ru
Návod k obsluze cs
Návod na obsluhu sk
Upute za uporabu hr
Navodila za uporabo sl
Ръководствозаобслужване bg
Instrucţiunideutilizare ro
KulllanmaTalimatı tr
ar
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Instrukcija lt
Kasutusjuhend et
Інструкціязексплуатації uk
Пайдаланубойыншабасшылы
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ja
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ORIGINAL OPERATING INSTRUCTIONS
DD 500 - CA core drilling machine
It is essential that the operating instructions
are read before the machine is operated for
the first time.
Always keep these operating instructions to-
gether with the machine.
Ensure that the operating instructions are
with the machine when it is given to other
persons.
Contents Page
1 General information 20
2Description 21
3 Technical data 23
4 Safety instructions 24
5 Preparation for core drilling 27
6 The core drilling operation 30
7 Care and maintenance 34
8 Troubleshooting 34
9Disposal 35
10 Manufacturer’s warranty 36
11 EC declaration of conformity (original) 36
1 These numbers refer to the illustrations. You can
find the illustrations at the beginning of the operating
instructions.
In these operating instructions, the designation “the ma-
chine” always refers to the DD 500-CA diamond core
drilling machine.
Core drilling machine 1
@
Control panel and display
;
Carrying bar
=
Type identification plate
%
Grip protrusion
&
Water drainage plug
(
3-way valve
)
Chuck
+
Connector
§
Supply cord guide
/
Water connection
:
Water flow regulator
·
Supply cord
Control panel and display 2
@
Gear selector
;
Drilling performance indicator
=
Temperature monitor / ground fault indicator
%
“On” switch
&
“Off” switch
(
Rebar button (Iron Boost)
)
Service indicator
Vacuum base plate (accessory) 3
@
Vacuum release valve
;
Vacuum hose connector
=
Vacuum seal
%
Pressure gauge
&
Wheel assembly mounting point
(
Leveling screws (4×)
DD‑HD 30 drill stand (accessory) 4
@
End stop with rail end cap
;
Leveling indicator (2×)
=
Carriage
%
Carrying grip (2×)
&
Brace
(
Leveling screw (3×)
)
Wheel assembly mounting point
+
Base plate
§
Rail
/
Carriage lock
:
Eccentricpin(forsecuringthemachine)
·
Hand wheel
$
Anchor position
£
Reduction gearing (1:3)
|
Direct drive (1:1)
¡
Type identification plate
Q
Hole center indicator
Drill stand fastening set (accessory) 4
W
Clamping nut
E
Anchor spindle
Water collection system (accessory) 4
R
Seal
T
Water collector
Z
Water collector bracket
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1 General information
1.1 Safety notices and their meaning
DANGER
Draws attention to imminent danger that will lead to
seriousbodilyinjuryorfatality.
WARNING
Draws attention to a potentially dangerous situation that
could lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation that
could lead to slight personal injury or damage to the
equipment or other property.
NOTE
Draws attention to an instruction or other useful informa-
tion.
1.2 Explanation of the pictograms and other
information
Prohibition signs
Transport by
crane is not
permissible.
Warning signs
General
warning
Obligation signs
Read the
operating
instructions
before use.
Symbols
Service
indicator
Return
materials for
recycling
Alternating
current
Nominal
speed under
no load
Diameter Drilling
performance
indicator
3-way valve on the core drilling machine
Wet drilling position
3-way valve on the core drilling machine
Core bit draining position
3-way valve on the core drilling machine
Dry drilling position
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
&
PD[EDU
VACUUM
VACUUM
On the core drilling machine
At temperatures below 4°C the cooling circuit must be
drained as described before pauses of an hour or longer
between use.
On the vacuum base plate
Upper: An additional means of securing the drill stand
must be employed when the machine is used for hori-
zontal drilling with the vacuum securing method.
Lower: Use of the vacuum securing method for overhead
drilling with the drill stand is not permissible.
Location of identification data on the machine
The type designation and serial number can be found on
thetypeidentificationplateonthemachine.Makeanote
of thisdata in your operating instructions andalways refer
to it when making an enquiry to your Hilti representative
or service department.
Type:
Generation: 01
Serial no.:
2 Description
2.1 Use of the product as directed
The core drilling machine together with the DD-HD 30 drill stand and additional accessories recommended by Hilti
(e.g. the DD AF-CA drilling feed unit) forms an automatic stand-mounted drilling rig suitable for wet core drilling in
reinforced mineral materials. The core drilling machine is electrically powered and is designed for drilling through holes
and blind holes using diamond core bits (it is not suitable for hand-held operation).
The core drilling machine must be mounted on the drill stand and care must be taken to ensure that the drill stand is
securely fastened to the base material using an anchor or vacuum base plate.
The machine is designed for professional use and may be operated, serviced and maintained only by trained,
authorized personnel. This personnel must be informed of any special hazards that may be encountered. The core
drilling machine, drill stand, accessories and core bits may present hazardswhenbyusedbyuntrainedpersonnel,
when handled incorrectly or when used not as directed.
Observe the national health and safety requirements.
Use of a water collection system connected to a wet/dry industrial vacuum cleaner is recommended for drilling in an
upward direction.
An additional means of securing the drill stand must be employed when the machine is secured with the vacuum base
plate (accessory) for horizontal drilling.
Do not use a hammer or other heavy object when making adjustments to the base plate.
NOTE
In addition to these operating instructions, the information given in the operating instructions for the other components
of the core drilling system, especially the operating instructions for the optional drilling feed unit, must always be
observed.
WARNING
The machine may be operated only when connected to an adequately-rated electric supply equipped with an
earth (ground) conductor.
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DANGER
Use only the genuine Hilti accessories or ancillary equipment listed in the operating instructions. Use of
accessories or ancillary equipment not listed in the operating instructions may present a risk of personal injury.
2.2 Use of the system with various items of equipment
Equipment
Core bit diameter
Drilling direction
Standard working
length
With water collection system 82…250 mm All directions 500 mm
System without water collection
system
82…600 mm All directions 500 mm
The core drilling machine complies with IP55 requirements and thus features protection against sprayed water. This
allows drilling to be carried out in all directions without use of a wet-type vacuum cleaner.
The machine may be operated only when an adequate supply of cooling water is ensured (at least 0.5 l/min at a water
temperature of max. 30°C) .
When the drilling column (rail) is extended to a length of 2 m or more, an additional support or brace must be fitted,
e.g. a bracing spindle.
2.3 Indicators on the control panel for service, cooling/voltage and drilling power
Service indicator Lights Bring the core drilling machine to a Hilti
Service Center
Blinks for a short time Faults or errors in the machine (see
Troubleshooting section)
Blinks continuously Bring the machine to a Hilti Service
Center immediately (failure to follow
this instruction may affect entitlement
to benefits under the optional 2-year full
service agreement!)
Indicators for cooling and voltage er-
ror
Lights Check the water flow rate
Blinks Check the electric supply (see
Troubleshooting section)
Drilling performance indicator Orange light Low contact pressure, e.g. when start-
ing drilling
Green light Optimum contact pressure (after the
hole has been started)
Red light Contact pressure too high
2.4 Gears and the corresponding core bit diameters
Gear Core bit diameter (mm) Core bit diameter (inches)
Speed under no load 380-
415 V (/min)
1 82…92
3¹⁄₄…3¹⁄₂
571
2 102…112
4…4¹⁄₂
571
3 122…132
4³⁄₄…5¹⁄₄
571
4 142…172
5¹⁄₂…6³⁄₄
571
5
182…202 7…8 510
6 225…250 9…10 429
7
300 12 367
8 350 14 327
9 400 16 286
10 450…600 18…24 265
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2.5 Items supplied
1 Core drilling machine
1 Operating instructions
NOTE
Accessories not supplied with the machine are available from your Hilti Center or can be ordered online at
www.hilti.com.
2.6 Using a generator or transformer
The core drilling machine may be powered by a generator or by way of site transformer when the following conditions
are fulfilled:
AC voltage, power output at least 10.000 VA
The operating voltage must, at all times, be no more than 5% above or 10% belowtheratedvoltage.
Frequency: 50 to 60 Hz, max. 65 Hz
Automatic voltage regulator with starting boost
NOTE
Switching other power tools, machines or appliances on and off may cause undervoltage and / or overvoltage peaks,
resulting in damage to the core drilling machine. Never operate other power tools, machines or appliances from the
generator or transformer at the same time.
3 Technical data
Right of technical changes reserved.
Other information about the machine
The core drilling machine is available in various voltage ratings. Please refer to the core drilling machine’s type
identification plate for details of its rated voltage and rated input power.
Rated voltage 380…415 V
Rated power input 5,500 W
Rated frequency 50…60 Hz
Rated speed under no load 270…580/min
Output voltage 380…415 V
Output frequency 50…60 Hz
Output current 0.25 A
Chuck BL (interchangeable, see www.hilti.com)
Max. permissible water supply pressure
1
6bar
Minimum water flow rate per minute Min. 0.5 l (water temperature: Max. +30°C)
Dimensions(LxWxH) 608mmx192mmx216mm
Weight in accordance with EPTA procedure 01/2003 16.6 kg
Weight of DD‑HD 30 drill stand 20.5 kg
Max. operating weight 83 kg (core drilling machine, drill stand, 600 mm core
bit)
Drilling depth Max. 500 mm without extension
Protection class I (grounded)
Protected against dust and water In accordance with IP 55
1
If the pressure is higher, use a pressure reduction valve!
NOTE
The vibration emission level given in this information sheet has been measured in accordance with a standardized test
giveninEN12348andmaybeusedtocompareonetoolwithanother.Itmaybeused for a preliminary assessment
of exposure. The declared vibration emission level represents the main applications of the tool. However if the tool is
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used for different applications, with different accessories or poorly maintained, the vibration emission may differ. This
may significantly increase the exposure level over the total working period. An estimation of the level of exposure to
vibration should also take into account the times when the tool is switched off or when it is running but not actually
doing the job. This may significantly reduce the exposure level over the total working period. Identify additional safety
measures to protect the operator from the effects of vibration such as: maintain the tool and the accessories, keep
the hands warm, organization of work patterns.
Noise and vibration information (measured in accordance with EN 12348/A1:2009)
Typical A-weighted sound power level 115 dB (A)
Uncertainty (K) for the sound power level 2.5 dB (A)
Typical A-weighted emission sound pressure level 100 dB (A)
Uncertainty (K) for the A-weighted emission sound
pressure level
4dB(A)
Total triaxial vibration values (vibration vector sum) at the hand wheel (star handle)
Drilling in concrete (wet), a
h, DD
4.5 m/s²
Uncertainty (K) 1.5 m/s²
4 Safety instructions
4.1 General Power Tool Safety Warnings
a)
WARNING
Read all safety warnings and all instructions. Fail-
ure to follow the warnings and instructions may result
in electric shock, fire and/or serious injury. Save all
warnings and instructions for future reference.
The term “power tool” in the warnings refers to
your mains-operated (corded) power tool or battery-
operated (cordless) power tool.
4.1.1Workareasafety
a) Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
b) Do not operate power tools in explosive atmo-
spheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
c) Keep children and bystanders away while operat-
ing a power tool. Distractions can cause you to lose
control.
4.1.2 Electrical safety
a) Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any ad-
apter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce
risk of electric shock.
b) Avoid body contact with earthed or grounded
surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet condi-
tions. Water entering a power tool will increase the
risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords increase
the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of
a cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is
unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk
of electric shock.
4.1.3 Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power tools
may result in serious personal injury.
b) Use personal protective equipment. Always wear
eye protection. Protective equipment such as dust
mask, non-skid safety shoes, hard hat, or hearing
protectionused for appropriate conditions willreduce
personal injuries.
c) Prevent unintentional starting. Ensure the switch
is in the off‐position before connecting to power
source and/or batterypack, picking up orcarrying
the tool. Carrying power tools with your finger on the
switch or energising power tools that have the switch
on invites accidents.
d) Remove any adjusting key or wrench before turn-
ing the power tool on. A wrench or a key left at-
tached to a rotating part of the power tool may result
in personal injury.
e) Do not overreach. Keep proper footing and bal-
ance at all times. This enables better control of the
power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
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away from moving parts. Loose clothes, jewellery
or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust
collection can reduce dust-related hazards.
4.1.4 Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application. The correct power
tool will do the job better and safer at the rate for
which it was designed.
b) Do not use the power tool if the switch does not
turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must be
repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of chil-
dren and do not allow persons unfamiliar with the
power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands
of untrained users.
e) Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and
any other condition that may affect the power
tool’s operation. If damaged, have the power tool
repaired before use. Many accidents are caused by
poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly main-
tained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits etc.
in accordance with these instructions, taking into
account the working conditions and the work to
be performed. Use of the power tool for opera-
tions different from those intended could result in a
hazardous situation.
4.1.5 Service
a) Haveyour power toolservicedbya qualified repair
person using only identical replacement parts.
This will ensure that the safety of the power tool is
maintained.
4.2 Proper organization of the work area
a) The machine may be operated only with a func-
tional ground fault circuit interrupter (RCD resid-
ual current device). Check each time before use
that your electric supply is equipped with a ground
fault circuit interrupter. Make sure that the ground
fault circuit interrupter is functioning.
b) Approval must be obtained from the site engineer
or architect prior tobeginningdrilling work. Drilling
work on buildings and other structures may influence
the statics of the structure, especially when steel
reinforcing bars or load-bearing components are cut
through.
c) When drilling through walls, secure (cordon off)
the area behind the wall, as material or the core
may fall out on the other side of the wall. When
drilling through ceilings, secure (cordon off) the
area below as drilled material or the core may
drop out and fall down.
d) In order to avoid accidents in which persons fall
and injure themselves, the opening that is created
must be securely and visibly cordoned off.
e) Place themounting device ona solid, flat and level
surface. If the mounting device can slip or wobble,
the machine cannot be guided smoothly and safely.
f) Check the nature of the surface.
Rough surfaces
may reduce the holding power of the drill stand.
Coatings or composite materials may pull away from
the surface while you are working, so that the drill
stand with the core drilling machine are no longer
held securely.
g) Do not overload the mounting device and do not
use it as a substitute for a ladder or platform.
Overloading the mounting device or standing on it
may shift its center of gravity to a higher position,
causingittotipover.
h) Wear respiratory protection if the work causes
dust.
i) Ensure that the workplace is well ventilated.
j) It is recommended that rubber gloves and non-
skid shoes are worn when working outdoors.
k) Keep the supply cord, extension cord, suction
hose and vacuum hose away from rotating parts.
l) Don’t work from a ladder.
m) Keep the workplace tidy. Objects which could
cause injury should be removed from the work-
ing area. Untidiness at the workplace can lead to
accidents.
n) Secure the workpiece. Use clamps or a vice to
secure the workpiece. The workpiece is thus held
more securely than by hand and both hands remain
free to operate the machine.
o) Always lead the supply cord and extension cord
away from the power tool to the rear while work-
ing. This helps to avoid tripping over the cord while
working.
4.2.1 General safety rules
a) Fit the protective cover cap only when the drilling
feed unit is unplugged. Operate the core drilling
machine only when the connecting socket is
covered, i.e.when the protective cover cap is fit-
ted. If the protective cover cap is missing, contact
Hilti Service and obtain a replacement. Unplug the
core drilling machine from the electric supply im-
mediately if water enters the connecting socket.
Check to ensure that the connecting socket is
dry before making further use of the core drilling
machine. The connecting socket may fill with water
if it is not covered by the protective cap or if the
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connecting plug is not in place, resulting in a risk of
electric shock if the parts are touched.
b) Keep the grips dry, clean and free from oil and
grease.
c) Never leave the machine unattended.
d) Store machines in a secure place when not in use.
When not in use, machines must be stored in a
dry, high place or locked away out of reach of
children.
e) Keep other persons away. Do not allow other per-
sons who are not involved in the work, especially
children, to touch neither the machine nor the
extension cable. Keep these persons away from
the working area.
f) Children must be instructed not to play with the
machine.
g) The machine is not intended for use by children,
by debilitated personsor thosewho have received
no instruction or training.
h) Never operate the machinewithout theRCD. Ifthe
machine has no RCD: never operate the machine
without an isolating transformer. Test the RCD
each time before use.
i) Tampering with or modification of the machine, drill
stand and accessories is strictly prohibited.
j) Check the machine and its accessories for any
damage. Guards, safety devices and any slightly
damaged parts must be checked carefully to en-
sure that they function faultlessly and as inten-
ded. Check that moving parts function correctly
without sticking and that no parts are damaged.
All parts must be fitted correctly and fulfill all
conditions necessary for correct operation of the
machine. Damaged guards, safety devices and
other parts must be repaired or replaced properly
at an authorized service center unless otherwise
indicated in the operating instructions.
k) Regularly check the hoses for damage and make
sure that the maximum permissible water supply
pressure of 6 bar is not exceeded.
l) Avoid skin contact with drilling slurry.
m) Wear a protective mask during work that gen-
erates dust, e.g. dry drilling. Connect a dust re-
moval system. Drilling in materials hazardous to
the health (e.g. asbestos) is not permissible.
n) Dust from material such as paint containing lead,
some wood species, minerals and metal may be
harmful. Contact with or inhalation of the dust may
cause allergic reactions and/or respiratory diseases
to the operator or bystanders. Certain kinds of dust
are classified as carcinogenic such as oak and beech
dust especially in conjunction with additives for wood
conditioning (chromate, wood preservative). Material
containing asbestos must only be treated by special-
ists. Where the use of a dust extraction device is
possible it shall be used. To achieve a high level
of dust collection, use a suitable vacuum cleaner
of the type recommended by Hilti for wood dust
and/or mineral dusttogether with thistool. Ensure
that the workplace is well ventilated. The use of a
dust mask of filter class P2 is recommended. Fol-
low national requirements for the materials you
want to work with.
o) Use the right tool or machine for the job. Do not
use the tool or machine for purposes for which
it was not intended. Use it only as directed and
when in faultless condition.
p) Check that all core bits are in good condition
before use. Do not use deformed or damaged
core bits.
q) When drilling, always maintain a safe distance
from the core bit and do not touch any rotat-
ing parts. Always unplug the supply cord before
touching or making any adjustments to the core
bit.
4.2.2 Mechanical
a) Follow the instructions concerning care andmain-
tenance.
b) Follow the instructions concerning lubrication
andchangingcorebits.
c) Check that the core bits used are compatible with
the chuck system and that they are secured in the
chuck correctly.
d) Make sure that the machine is correctly and se-
curely mounted on the drill stand.
e) Do not touch rotating parts.
f) Check that all the clamping screws are correctly
tightened.
g) As the end stop has a safety-relevant function,
always check to ensure that the end stop screw
is securely in place on the drill stand.
4.2.3 Electrical
a) Check the machine’s supply cord at regular inter-
vals and have it replaced by a qualified specialist
if found to be damaged. Check extension cords
at regular intervals and replace them if found to
be damaged.
b) Do not touch the supply cord or extension cord
if it is damaged while working. Disconnect the
supply cord plug from the power outlet.
c) In case of an interruption in the electric supply:
Switch the machine off and unplug the supply
cord.
d) Avoid using extension cords with multiple power
outlets and the simultaneous use of several elec-
tric toolsor machines connectedto one extension
cord.
e) Never operate the machine when it is dirty or
wet. Dust (especially dust from conductive ma-
terials) or dampness adhering to the surface of
the machine may, under unfavorable conditions,
lead to electric shock. Dirty or dusty machines
should thus be checked at a Hilti service center
at regular intervals, especially if used frequently
for working on conductive materials.
f) Before beginning work, check the working area
(e.g. using a metal detector) to ensure that no
concealed electric cables or gas and water pipes
are present. External metal parts of the machine may
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become live, for example, when an electric cable is
damaged accidentally. This presents a serious risk of
electric shock.
g) Before beginning drilling, check that there are
no live electric cables present in the area where
drilling is to take place.
4.2.4 Thermal
Wear protective gloves when changing core bits. The
core bit may become hot during use.
4.2.5 Requirements to be met by users
a) Improve the blood circulation in your fingers by
relaxing your hands and exercising your fingers
during breaks between working.
b) Stay alert. Pay attention to what you are doing.
Approach the work with common sense. Do not
use the machine if you are not concentrating.
5 Preparation for core drilling
WARNING
While setting up the equipment, the core drilling machine
must be disconnected from the electric supply.
DANGER
Check that the drill stand is securely fastened to the work
surface.
CAUTION
Themachineandthediamondcorebitareheavy.
There is a risk of pinching parts of the body.
Wear a hard hat, protective gloves and safety boots.
NOTE
When carrying the drilling machine, use the carrying
handle and the grip protrusion provided.
5.1 Setting up the drill stand 5
These steps are necessary only if the parts of the drill
stand have been folded together.
1. Loosen the bolt at the top end of the brace and at
the pivoting joint at the bottom end of the rail.
2. Bring the rail into the vertical position.
3. Tighten the bolt at the top end of the brace and at
the pivoting joint at the bottom end of the rail.
4. CAUTION The protective end cap with built-in
end stop must be fitted at the top end of the
guide rail.
If the protective end cap with built-in end stop is not
already fitted, fit it now.
5.2 Fitting the hand wheel
The hand wheel can be fitted on the left-hand side or the
right-hand side of the carriage on two different shafts.
On both sides of the carriage, the upper shaft provides
a direct drive while the lower shaft drives the carriage
through reduction gearing.
1. Fit the hand wheel onto one of the two shafts on the
left-hand or right-hand side of the carriage.
2. Secure the hand wheel with the screw.
5.3 Fastening the drill stand with an anchor 6
WARNING
Use an anchor suitable for the material on which you
are working and observe the anchor manufacturer’s
instructions.
NOTE
Hilti M16metal expansion anchors are usually suitable for
fastening diamond core drilling equipment to uncracked
concrete. Under certain conditions it may be necessary
to use an alternative fastening method. Please contact
Hilti Technical Service if you have any questions about
secure fastening.
1. If you are working without a spacer, the anchor for
the base plate should be set, as far as possible, at
a distance of 330 mm (13 ") from the center of the
hole to be drilled.
NOTE The optimum distance is 330 mm (13 "). If a
spacer is used, this distance increases.
2. Screw the anchor spindle into the anchor.
3. Placethedrill stand overtheanchor spindle and then
use the hole center indicator to position it correctly.
NOTE If a spacer is fitted, the hole center indicator
cannot be used to position the drill stand.
4. Screw the clamping nut onto the anchor spindle,
leaving it loose enough to allow movement of the
base plate.
5. Level the base plate by turning the 3 leveling screws.
Use the 2 leveling indicators on the carriage as an
aid. Take care to ensure that the leveling screws
make firm contact with the underlying surface.
6. Use a 27 mm AF open-end wrench to tighten the
clamping nut on the anchor spindle.
NOTE Do not use a hammer or other heavy object
when tightening the nut as this can damage the base
plate. The brace can be released and folded out of
the way to allow better access. Before operating the
machine, however, the brace must be refitted and
securely attached to the rail.
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7. Make sure that the drill stand is fastened securely.
5.4 Fastening the drill stand with the vacuum base
plate 7
DANGER
A coated, laminated, rough or uneven surface may signi-
ficantly reduce the effectiveness of the vacuum system.
Check whether the surface is suitable for use of the
vacuum method to fasten the drill stand.
CAUTION
Suitable for use only with core bits ≤ 300 mm in
diameter and without the use of a spacer.
DANGER
Overhead drilling with the machine secured by the
vacuum base plate is not permissible.
NOTE
A vacuum valve, which can be used to release the va-
cuum, is fitted to the hand grip on the vacuum base
plate.
Check the condition of the seal on the vacuum base plate
at regular intervals and replace it if it is worn or damaged.
The vacuum base plate is available as an accessory.
1. Turn the four leveling screws until they project ap-
proximately 5 mm beneath the vacuum base plate.
2. Connect the vacuum connector on the vacuum base
plate to the vacuum pump.
3. Place the drill stand on the vacuum base plate.
4. Fasten it securely using the screw and washer sup-
plied.
5. Locate the center point of the hole to be drilled.
6. Beginning at the center point of the hole to be drilled,
mark out a line with a length of approx. 800 mm in
the direction of where the core drilling system is to
stand.
7. At a distance of 165 mm (6 ½") from the center point
of the hole to be drilled, make a mark on the 800 mm
long line.
8. Bring the indicator marks on the vacuum base plate
into alignment with the 800 mm long line.
9. Align the middle of the front edge of the vacuum
baseplatewiththemarkat165mm(6½")onthe
line.
10. CAUTION Make yourself familiar with informa-
tion contained in the operating instructions for
the vacuum pump and follow these instructions
before using it.
Switch on the vacuum pump and press the vacuum
release valve.
11. Adjust the position of the drill stand while keeping
the vacuum release valve pressed in. Release the
valve as soon as the drill stand is correctly po-
sitioned. Press the drill stand against the working
surface.
12. WARNING Before beginning drilling, during
drilling and until the core drilling system is
dismantled, it must be ensured that the pressure
gauge indicator remains within the green area.
WARNING The anchor base plate cannot and
should not be leveled on the vacuum base plate.
Level the vacuum base plate by turning the four
leveling screws.
NOTE The two leveling indicators incorporated in
the carriage serve as an adjustment aid.
13. An additional means of securing the drill stand must
be used when drilling horizontally. (e.g. a chain at-
tached to an anchor, etc.).
14. Make sure that the drill stand is fastened securely.
5.5 Setting the drilling angle on the drill stand 8
The drilling angle can be adjusted to a maximum of 45°.
CAUTION
At the hinged joints on the drill stand there is a risk of
crushing the fingers. Wear protective gloves.
1. Loosentheboltatthetopendofthebraceandat
the pivoting joint at the bottom end of the rail.
2. Adjust the rail to the desired angle.
NOTE The angle scale at the rear serves as an
adjustment aid.
3. Tighten the bolt at the top end of the brace and at
the pivoting joint at the bottom end of the rail.
5.6 Extending the rail 9
CAUTION
When starting holes use only core bits or extended
core bits with a maximum total length of 650 mm.
1. Remove the protective end cap with built-in end
stop from the top end of the rail.
2. Fit the protective end cap with built-in end stop to
the end of the extension rail.
NOTE In addition, a depth gauge (accessory) can
also be fitted at the lower end of the rail.
3. Fit the cylindrical connector on the extension rail
into the end of the rail on the drill stand.
4. Secure the extension rail by turning the eccentric
pin.
NOTE After removing the extension rail, the pro-
tective cover cap must be refitted to the rail on the
drill stand in order to ensure that safety-relevant end
stop function is restored.
5.7 Fitting the spacer 
NOTE
When core bits with a diameter of 300 mm or greater
are used, the distance between the drill stand and the
drilling axis must be increased by fitting a spacer. The
hole center indicator is no longer functional when spacers
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28
Printed: 12.11.2015 | Doc-Nr: PUB / 5209085 / 000 / 02
are used. A maximum of 2 spacers may be fitted, one
behind the other.
At this stage, the core drilling machine should not already
be mounted on the drill stand.
1. Lockthecarriageinpositionontherailandcheck
that it holds securely.
NOTE The carriage is locked when the locking pin
is engaged.
In this position, no movement of the carriage is
possible.
2. Pull the eccentric pin out of the core drilling machine
mount.
3. Fit the spacer onto the carriage.
4. Push the eccentric pin into the carriage as far as it
will go.
5. Use the hand wheel to tighten the eccentric pin
moderately in a clockwise direction.
NOTE The locking pin will shear if excessive force
is applied.
5.8 Mounting the machine on the drill stand 
1. Lockthecarriageinpositionontherailandcheck
that it holds securely.
NOTE The carriage is locked when the locking pin
is engaged.
In this position, no movement of the carriage is
possible.
2. Pull the eccentric pin out of the core drilling machine
mount.
3. Fit the machine onto the carriage or the spacer.
4. Push the eccentric pin intothe carriage orthe spacer
as far as it will go.
5. Use the hand wheel to tighten the eccentric pin
moderately in a clockwise direction.
NOTE The locking pin will shear if excessive force
is applied.
6. Pass the supply cord through the supply cord guide
on the opposite side of the carriage.
7. Check that the machine is mounted securely.
5.9 Fitting the water supply connection
NOTE
Before starting the core drilling machine, check that the
3-way valve is set to the position for wet drilling or dry
drilling.
1. Close the valve in the water supply hose.
2. Connect the water supply hose to the hose con-
nector on the core drilling machine.
NOTE A flow meter, which is available as an ac-
cessory, may be fitted between the machine’s water
supply hose connector and the water supply hose.
5.10 Fitting the water collection system
(accessory) 
NOTE
Use of the water collection system allows water to be
led away in a controlled manner, thus avoiding a mess
or damage to the surrounding area. We recommend, as
a general rule, that a water collection system is used
with core bits of up to 250 mm in diameter. Best results
are achieved with a wet-type industrial vacuum cleaner.
When drilling overhead on ceilings, the drill stand must
be perpendicular to the ceiling (90°) and the sealing ring
must correspond to the diameter of the diamond core bit
used.
1. Release the screw on the front of the rail at the
hinged joint on the drill stand.
2. Slide the water collector holder into position under
the screw from below.
3. Tighten the screw securely.
4. Fit the water collector between the two movable
arms of the water collector holder.
5. Secure the water collector with the two screws on
the holder.
6. Connect a wet-type industrial vacuum cleaner to the
water collector or fit a length of hose through which
the water can drain away.
5.11 Fitting the diamond core bit (BL chuck) 
DANGER
Fitting and positioning the core bit incorrectly can lead
to hazardous situations as this may cause parts to break
and fly off. Check that the core bit is seated correctly.
DANGER
Do not use damaged core bits. Check the core bits for
chipping, cracks, or heavy wear each time before use.
Do not use damaged tools. Fragments of the workpiece
orabrokencorebitmaybeejectedandcauseinjury
beyond the immediate area of operation.
NOTE
Diamond core bits must be replaced when the cutting
performance and/or rate of drilling progress drops sig-
nificantly. This generally is the case when the segments
reach a height of less than 2 mm.
CAUTION
The core bit may get hot during use or during sharpening.
There is a risk of burning your hands. Wear protective
gloves when changing the core bit.
1. Disconnect the supply cord plug from the power
outlet.
2. Lock the carriage in position on the rail and check
that it is securely locked by turning the hand wheel
slightly.
3. From below, push the connection end of the dia-
mond core bit into chuck on the core drilling ma-
chine, making sure that the teeth engage.
4. Close the chuck by turning it in the direction of the
closed brackets symbol.
5. Checkthatthe diamond core bitis securely mounted
in the chuck. There should be no movement when it
is gripped and pulled.
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PLQFP
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6. WARNING The rotating core bit presents a risk of
injury! A rotating core bit that is lowered toward
the base material is capable of severing parts of the
body. After fitting the core bit, adjust the system in
order to reduce the distance between the core bit
andthe base materialtoa minimum before switching
on the diamond coring machine.
Bring the core bit as close as possible to the
surface in whichthe hole is to be drilled. However,
it should not touch the surface.
5.12 Setting the depth gauge (accessory)
1. Turn the hand wheel until the diamond core bit is in
contact with the surface in which the hole is to be
drilled.
2. Set the desired drilling depth by adjusting the dis-
tance of the depth gauge from the carriage.
3. Secure the depth gauge by tightening the clamping
screw.
5.13 Selecting the speed
1. Select the switch setting according to the core bit
diameter used.
NOTE The speed of rotation of the core bit can be
changed while drilling is in progress.
6 The core drilling operation
CAUTION
The AC supply voltage must correspond to the voltage
rating given on the type identification plate.
DANGER
Have the earth / ground conductor installation in the
mains supply and the earth / ground connection in the
machine checked at regular intervals.
WARNING
Take care to ensure that the supply cord does not come
into contact with rotating parts.
WARNING
Make sure that the supply cord is not pinched and dam-
aged as the carriage advances.
CAUTION
The machine and the drilling operation generate noise.
Wear ear protectors.
Excessive noise may damage the hearing.
CAUTION
Drilling may cause hazardous flying fragments.
Flying fragments present a risk of injury to the eyes and
body.
Wear eye protection and a hard hat.
DANGER
When drilling through walls, secure (cordon off) the area
behind the wall, as material or the core may fall out on
the other side of the wall. When drilling through ceilings,
secure (cordon off) the area below as drilled material or
the core may drop out and fall down.
CAUTION
Take care to avoid touching rotating parts when regulat-
ing the water flow while the machine is running.
6.1 Keep everything clear of the danger zone
The shaded area in the illustration indicates the danger
zone around the core drilling machine. When operating
the machine, always keep everything at least 15 cm away
from the core bit.
Position yourself behind the drill stand (see illustra-
tion) while drilling is in progress.
6.2 Starting a hole using the hole-starting function
NOTE
Pay attention to the information in this section in ad-
dition to the information about the various core drilling
applications.
Strong vibration may occur when starting a hole. Use the
hole-starting function if strong vibration is experienced.
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Hilti DD 500-CA Operating instructions

DD 500-CA
Hilti
Brand
Hilti
Model
DD 500-CA
Category
Power tools
Type
Operating instructions
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